Our 2005 4-Runner has awful rust issues. The entire frame is rusted and with only 40,000 miles on it, it is not able to be driven. Has anyone else had these issues?! Is there anything that can be done? Yes, we have contacted Toyota, and they have offered us $1000 towards a new car. Ya,, thanks!!

Here is the deal. You live in the north east. You have crap winters and they know that. This could have be headed off with good maint. To the frame over that last ten years. Both of my 4runners are over 15 now and I li e in the mid west. Both the frames a rock solid because they were taken care of. I'm not try to be Debbie downer but that's the reality of it.

Toyota had to replace the frames in the tacoma because of this but not the 4runners that I know of yet anyhow.

Post some pics so we can all see how bad it really is that might help us better under stand also. We're is it at. Is it by critical point etc.

Here is the deal. You live in the north east. You have crap winters and they know that. This could have be headed off with good maint. To the frame over that last ten years. Both of my 4runners are over 15 now and I li e in the mid west. Both the frames a rock solid because they were taken care of. I'm not try to be Debbie downer but that's the reality of it.

Toyota had to replace the frames in the tacoma because of this but not the 4runners that I know of yet anyhow.

Post some pics so we can all see how bad it really is that might help us better under stand also. We're is it at. Is it by critical point etc.

Your rust situation is really nothing. Coming from someone who has restored 4 Austin Healeys over the years. In fact less than on my New England 2006 Limited. My only "unusual " repair in 165,000 miles of personal ownership since new, a rusting out radiator. That area takes a lot of crap around here. Even frequent underbody washes are almost useless here, but once the chloride goes down, it just hangs around until May !

I am the original owner of a 2005 4RUNNER Limited. My vehicle has only 61,500 miles registered on the odometer...This SUV has never been involved in any accident. I just noticed the frame has severe corrosion...The safety and integrity of the vehicle and its passengers has been compromised by the severe deterioration of the chassis. I have notified Toyota of the condition and requested their inspection of my vehicle...Hoping Toyota will remedy this mater...If not, I'll pursue other means for a resolution.

I am the original owner of a 2005 4RUNNER Limited. My vehicle has only 61,500 miles registered on the odometer...This SUV has never been involved in any accident. I just noticed the frame has severe corrosion...The safety and integrity of the vehicle and its passengers has been compromised by the severe deterioration of the chassis. I have notified Toyota of the condition and requested their inspection of my vehicle...Hoping Toyota will remedy this mater...If not, I'll pursue other means for a resolution.

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I have an 05 with the same rust issue on the support below the radiator. What ever happened with your request to Toyota?

I have an 04 4 Runner. Live in Virginia, so our winters are not bad. The frame is rusted so bad that it failed inspection today. I know a bit about welding and this is not repairable short of swapping out the frame.. odometer just clicked over 100K. Thanks Toyota.
Before anyone starts telling me it is due to poor maintenance, I have owned vehicles for 45 years. I have never seen anything like this. It appears to be rusting from the inside out. I’m not talking surface rust. It is coming off in chunks.
Guess I’ll be joining the Jeep forum, because I’ll never buy another Toyota if the company doesn’t stand behind this.

I have an 04 4 Runner. Live in Virginia, so our winters are not bad. The frame is rusted so bad that it failed inspection today. I know a bit about welding and this is not repairable short of swapping out the frame.. odometer just clicked over 100K. Thanks Toyota.
Before anyone starts telling me it is due to poor maintenance, I have owned vehicles for 45 years. I have never seen anything like this. It appears to be rusting from the inside out. I’m not talking surface rust. It is coming off in chunks.
Guess I’ll be joining the Jeep forum, because I’ll never buy another Toyota if the company doesn’t stand behind this.

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There is currently a NHTSA investigation that started back in August but I wouldn’t get my hopes up, and I doubt it will be a timely investigation either.

Jeep was no better at one point in time. They are practically the reason why frame reinforcement caps were made.

I have an 04 4 Runner. Live in Virginia, so our winters are not bad. The frame is rusted so bad that it failed inspection today. I know a bit about welding and this is not repairable short of swapping out the frame.. odometer just clicked over 100K. Thanks Toyota.
Before anyone starts telling me it is due to poor maintenance, I have owned vehicles for 45 years. I have never seen anything like this. It appears to be rusting from the inside out. I’m not talking surface rust. It is coming off in chunks.
Guess I’ll be joining the Jeep forum, because I’ll never buy another Toyota if the company doesn’t stand behind this.

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I totally agree it's 2019 it's totally unacceptable to be expected (or for the mfg to expect) owners to get on their backs and spray their frames with rust inhibiter! O.K. I get some people do and great for them but surely 95% of the driving population doesn't do it including me. In 5 or 6 years my 2018 SR5 will be gone I'll just trade it in and avoid the issues. Had the vehicle five months now and from what I've seen I'll be perfectly fine letting it go when it's time I'm obviously not so overly impressed with it as other hard-core owners are. For the money spent I'm reading about to much $hit about them.

Regarding this frame rust problem. I just got off the phone with Toyota Customer Service. The customer service agent said that they do not follow forums on the Internet. They do take this seriously and that everyone who is experiencing this problem should call Toyota and they will issue you a case number. If they get enough complaints, they might issue a voluntary service repair. At least you have put them on notice of this safety hazard.
I’m not holding my breath, but I am pissed.
Side bar. There is a shop near me in VA that is completely aware of the problem and offers to weld reinforcing metal to the frame (if possible) then coat the entire frame to prevent further damage. Cost about $1,000. As stated in previous post, I know a bit about welding and doubt this is possible on my 4 Runner.

I still don’t understand how Tacoma’s get frame recalls and 4Runners don’t. Is there a reason behind this? Were the frames made by different companies?

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4runner frames were made in Japan. As opposed to all the recall frames made or coated by Dana.

I think the issue with the 4runner frame isn’t so much the strength or quality of coating but rather the allowed collection of fluids in places that lead to accelerated rust, when if adequate drainage was provided, this probably wouldn’t be a problem. Namely, rear trailing arm mount area and the front auxiliary rad bracket that the trans cooler lines and skid plate mount to. Compounding living in a salty environment only makes it 100x worse.

4runner frames were made in Japan. As opposed to all the recall frames made or coated by Dana.

I think the issue with the 4runner frame isn’t so much the strength or quality of coating but rather the allowed collection of fluids in places that lead to accelerated rust, when if adequate drainage was provided, this probably wouldn’t be a problem. Namely, rear trailing arm mount area and the front auxiliary rad bracket that the trans cooler lines and skid plate mount to. Compounding living in a salty environment only makes it 100x worse.

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That makes sense. I have noticed the only serious rust on mine is on the lower radiator bracket where the skid plate mounts. I’m guessing since quality wasn’t a problem Toyota doesn’t want to own up to a design flaw.

That makes sense. I have noticed the only serious rust on mine is on the lower radiator bracket where the skid plate mounts. I’m guessing since quality wasn’t a problem Toyota doesn’t want to own up to a design flaw.

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Like I posted above, there is a current open NHTSA investigation into the rust matter, but I’m not holding my breath.

JDEVTAC’s response is the one that makes the most sense. As I stated, my 4Runner appears to be rusting from the inside out. So holding water would explain this. Maybe weep holes would have prevented this problem. I suspected that they sprayed the frames instead of dipping them in rust preventative.
My 4RUNNER is at the frame repair shop now so I cannot go out and look at it, but I seem to remember some pretty severe rust on the upper parts of the frame where it goes over the rear axle. If this is the case, it might throw some water on this theory. Pun intended.

Still say this is ridiculous and I personally refuse to go outside, lay on my back and spray the whole bottom with some goopy $hit or whatever it is. My god there has been inventions to stop or greatly slow rust it is 2019 isn't it. I've got an '18 but if and when it ever STARTS to look concerning I'm getting rid of it and will not buy another. Yeah I get "taking care of my stuff" and all my motorized tools look and run like their a month old (some 10+ yrs) so I don't buy that. ok rant over...

Just found this site and signed up today ,never joined a forum so going to give it a shot, I have a 2005 4Runner sport edition 6 cylinder 4 wheel drive with only 60,000 miles mostly highway, bought it brand new but it had 1000 miles from an executive driving it, the support below the radiator is almost completely gone from rust, also the brush guard is falling apart from rust, never been driven on salt roads and I live in Southeast Louisiana, the rest of the frame ain't too bad as far as I can tell, this vehicle was kept very clean so can't believe this happened, had a warranty for the first seven years but didn't expect something like this so didn't keep it under warranty any longer. Had to take early retirement so was hoping this would last the rest of my days, if I lived up north I imagine the frame would be gone by now, this is ridiculous, I looked underneath a 2007 around the block from me and it's got over 100,000 miles but the frame looks like new! Hurricane Katrina hit in 2005 and maybe wondered if mine had sat in saltwater or something, it looked clean when I bought it new, appreciate any further comments.

Just found this site and signed up today ,never joined a forum so going to give it a shot, I have a 2005 4Runner sport edition 6 cylinder 4 wheel drive with only 60,000 miles mostly highway, bought it brand new but it had 1000 miles from an executive driving it, the support below the radiator is almost completely gone from rust, also the brush guard is falling apart from rust, never been driven on salt roads and I live in Southeast Louisiana, the rest of the frame ain't too bad as far as I can tell, this vehicle was kept very clean so can't believe this happened, had a warranty for the first seven years but didn't expect something like this so didn't keep it under warranty any longer. Had to take early retirement so was hoping this would last the rest of my days, if I lived up north I imagine the frame would be gone by now, this is ridiculous, I looked underneath a 2007 around the block from me and it's got over 100,000 miles but the frame looks like new! Hurricane Katrina hit in 2005 and maybe wondered if mine had sat in saltwater or something, it looked clean when I bought it new, appreciate any further comments.

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Do you go to the beach with it? Usually if your not in the Northeast then the next worst enemy is salty air or saltwater, and if it was flooded to the frame during hurricanes then that is another possibility.

We will see how it all pans out, but there is currently a class action lawsuit started up over 2005-2011 4Runners as well as an open NHTSA investigation into 02-09 model years for rust. Why the lawsuit involves 05-11 I have no idea, and is stupid considering 4th gens span manufacturing dates from 02-08/09.

I’m not one for handouts but the 2004 I bought last September timeframe had to have frame repair and I have not the time not money nor space to swap frames. We will see how this all pans out in maybe a year or 2 at the earliest considering how slow all this stuff moves. It would be great if I can get the frame fixed, especially considering my vehicle had been a Virginia owned 4runner all its life and where the rust came from in this region who the hell knows.

Never go to the beach with it because I cannot take the sun, don't live near the beach either but more inland, I know all about salt air and also the North cuz I was born and raised in Ohio and lived in Michigan also, I remember the rusted out cars back in the 70s and 80s, I did auto body work back then, ha, up until now I had an old beater for a second vehicle if I did venture out in bad weather, sounds like it was hit and miss on these Toyota frames, maybe a bad batch of steal or like somebody said not proper drain holes in the places they need to be, is this class action suit something that will be mailed to me automatically or do I need to call somebody? Most vehicles down in this area that are older than mine have less rust underneath, only ones that may rust is down on the bayou near the coast where they made drive their vehicles through flood water at times, I had a second-hand 1994 minivan that had no rust under it, somewhere there's a flaw in these 4Runners and if I did have this vehicle up north I got a feeling the rest of the frame would be shot by now, I have four-whee drive but never took it off Road, it's never sat in or been driven in flood water whatsoever, like I said there's an 07 4Runner around the block with twice as many miles but looks brand-new underneath, it's a lady with kids who I'm sure don't take as good a care of hers as I take care of mine so it don't make sense. Thank you for the information and let me know about that class action please.

Still say this is ridiculous and I personally refuse to go outside, lay on my back and spray the whole bottom with some goopy $hit or whatever it is. My god there has been inventions to stop or greatly slow rust it is 2019 isn't it. I've got an '18 but if and when it ever STARTS to look concerning I'm getting rid of it and will not buy another. Yeah I get "taking care of my stuff" and all my motorized tools look and run like their a month old (some 10+ yrs) so I don't buy that. ok rant over...

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An that is your choice. I actually like taking care of my 4. Its fun to me. The yearly laying on my back and spraying fluid film under it also lets me examine under there and identify any possible issues. If I could change anything about it, it would be to have the ability to have a rack in my yard so I don't have to roll around on the dirt anymore, but it's really no big deal.

Never go to the beach with it because I cannot take the sun, don't live near the beach either but more inland, I know all about salt air and also the North cuz I was born and raised in Ohio and lived in Michigan also, I remember the rusted out cars back in the 70s and 80s, I did auto body work back then, ha, up until now I had an old beater for a second vehicle if I did venture out in bad weather, sounds like it was hit and miss on these Toyota frames, maybe a bad batch of steal or like somebody said not proper drain holes in the places they need to be, is this class action suit something that will be mailed to me automatically or do I need to call somebody? Most vehicles down in this area that are older than mine have less rust underneath, only ones that may rust is down on the bayou near the coast where they made drive their vehicles through flood water at times, I had a second-hand 1994 minivan that had no rust under it, somewhere there's a flaw in these 4Runners and if I did have this vehicle up north I got a feeling the rest of the frame would be shot by now, I have four-whee drive but never took it off Road, it's never sat in or been driven in flood water whatsoever, like I said there's an 07 4Runner around the block with twice as many miles but looks brand-new underneath, it's a lady with kids who I'm sure don't take as good a care of hers as I take care of mine so it don't make sense. Thank you for the information and let me know about that class action please.

The firm handling the lawsuit is Bell Legal Group:Gary Weinreich v. Toyota Motor Sales USA Inc., et al., Case No. 2:18-cv-03294-RMG, in the U.S. District Court for the District of South Carolina, Charleston Division.

Thanks for the info jdevtac, from what I understand the forerunners have the same frames as the tacomas, so it puzzles me why they didn't also recall the forerunners, the vehicle itself says made in Japan, I really do like the 4Runner so this really sucks!

Thanks for the info jdevtac, from what I understand the forerunners have the same frames as the tacomas, so it puzzles me why they didn't also recall the forerunners, the vehicle itself says made in Japan, I really do like the 4Runner so this really sucks!

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I can sympathize.

The reasoning seems to be that since the 4Runner frames were made in Japan that they were made better, rather than the Tacoma/Tundra/Sequioa frames made by DANA here in the USA. However in reality if the frames are crap the frames are crap, who is to say the 4Runner frames aren’t also flawed in some way.

All I know is they don’t drain well enough in a few key spots as evidenced by the rust posts and seem apt to rust in those areas. The frame I have is the exact same rust pattern as other pics I’ve seen. And consequently follows a similar rust pattern as early jeeps that fell apart near their rear axles due to poor drainage. It’s the same reason why the front auxiliary crossmember falls apart, it holds water. Add in any salt exposure and it only gets compounded.

Still makes me wonder if it ain't just bad steel because living in the South and only 60,000 mile I would think it would be in better shape, is there drain holes in the front piece that goes under the radiator?, because mine is pretty much completely gone, nothing much there to protect those transmission lines and what's left of the brush guard is no where to bolt the front of it to.

Well I’ve been sort of following the court case online as best as I can without spending money on document acquisition. Anyway, Toyota basically looks like it’s trying to get the case thrown out of course. I dropped an email to the law firm as well and I guess short of an actual phone call they probably won’t respond and/or can’t discuss much due to confidentially.

If this thing somehow possibly goes through and a frame recall is done, I’ll be pissed if it only covers the 2005-2011 year range in the suit which is dumb as hell if you ask me.

Well I’ve been sort of following the court case online as best as I can without spending money on document acquisition. Anyway, Toyota basically looks like it’s trying to get the case thrown out of course. I dropped an email to the law firm as well and I guess short of an actual phone call they probably won’t respond and/or can’t discuss much due to confidentially.

If this thing somehow possibly goes through and a frame recall is done, I’ll be pissed if it only covers the 2005-2011 year range in the suit which is dumb as hell if you ask me.